Method for the connection of sheet metal parts and component assembly as well as setting head and die button

ABSTRACT

A component assembly having a stacked arrangement comprising an upper and lower sheet part, of which at least one is formed as an organic sheet composite part, with an auxiliary joining part and with at least one apertured metal washer, wherein the auxiliary joining part has a functional section having an undercut at one end and also has a piercing section at the other end having a lateral shaft surface and a shaft recess formed therein, wherein the metal washer contacts a surface of the organic sheet composite part, with the functional section or the piercing section extending through an aperture of the metal washer and wherein washer material has been driven into the undercut or into the at least one shaft recess.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is a continuation of, and claims priority to,U.S. patent application Ser. No. 14/533,361, filed Nov. 5, 2014, whichclaims priority to German Patent Application No. 102013222569.5, filedNov. 6, 2013, as well as German Patent Application No. 102014113438.9,filed Sep. 17, 2014, the disclosure of each incorporated herein byreference in their entireties.

BACKGROUND

The disclosure herein relates to a method for joining an upper sheetmetal part and of a lower sheet metal part of which at least one isformed as an organic sheet metal part.

Components are termed organic sheet metal parts which as a result oftheir table-like form can be handled like sheet metals, but whichconsist of a non-metallic composite material such as a fiber or fabricreinforced plastic. Such composite materials generally have highstrength fibers, such as, for example aramid fibers, carbon fibers orglass fibers, which are either present as relatively short fillingfibers or as long filaments or in the form of a fabric fabricated fromfilaments embedded in a matrix material of plastic. Thermoplasticmaterials can indeed be used as plastic; however, for coachworkcomponents, duroplastic plastics are normally used. In the coachworkconstruction and in other fields of technology organic sheet metal partsare increasingly being used as a result of their characteristics such astheir lightness, their high mechanical loadability and their gooddeformability.

A problem in the connection of two organic sheet metal parts or of anorganic sheet metal part to a metallic sheet metal part consists howeverin the fact that some current joining processes, such as, e.g. theself-pierced rivet process are not suitable for fiber or fabricreinforced plastics.

The requirement thus exists to enable a simple and effective joining ofsheet metal parts of which at least one is an organic sheet metal part.

SUMMARY

According to an aspect of the disclosure, provided is a method for theconnection of an upper sheet part and a lower sheet part of which atleast one is executed as an organic sheet composite part, with the aidof an auxiliary joining part and at least one metal washer having anaperture, wherein the auxiliary joining part has first and second ends,there being a functional section with an undercut at one of said endsand a piercing section with a lateral shaft surface and a shaft recessformed therein at the other of said ends. The method includes the uppersheet part, the lower sheet part and the metal washer being brought intoa stacked arrangement in such a way that the metal washer contacts theorganic sheet composite part. The method also includes the piercingsection of the auxiliary joining part used in order to pierce a slugfrom the stacked sheet parts. Either the functional section or thepiercing section is passed through an aperture of the metal washer untilthe undercut or the at least one shaft recess is at least partlysurrounded by washer material. An adequate pressure is exerted on themetal washer in order to drive washer material into the at least oneshaft recess or into the undercut and thereby to join the auxiliaryjoining part to the metal washer. The other respective one of theundercut or of the shaft recess is brought into a holding engagementwith a sheet part formed as a sheet metal part or with a further metalwasher, with the sheet metal part or the further metal washer beinglocated at the side of the stacked arrangement remote from the firstmetal washer.

According to another aspect of the disclosure, provided is a method forthe connection of an upper sheet part and of a lower sheet part of whichat least one is formed as an organic sheet composite part, with the aidof an auxiliary joining part which has a first end and a second end andalso with the aid of a pierced metal washer. The method includes theupper sheet part, the lower sheet part and the metal washer beingbrought into a stacked arrangement in such a way that the metal washercontacts the organic sheet composite part. The method also includes apiercing section of the auxiliary joining part exploited to punch a slugfrom the stacked sheet parts. The first end of the auxiliary joiningpart is passed through an aperture of the metal washer to such an extentthat it is at least partly surrounded by washer material, and, either.An adequate pressure is exerted onto the sheet metal washer in order todrive washer material into at least one undercut of the first end of theauxiliary joining part, in order to join the auxiliary joining part tothe metal washer. The first end of the auxiliary joining part isembossed in order to hereby join the auxiliary joining part in theregion of the first end to the metal washer and the second end of theauxiliary joining part either is brought by embossing into a holdingengagement with a sheet part formed as a sheet metal part or with afurther metal washer, with the sheet metal part or the metal washerbeing located at the side of the stacked arrangement remote from thefirst metal washer; or is joined by deformation of the sheet metal partor by deformation of a further metal washer to the sheet metal part orto the further metal washer, with the sheet metal part or the furthermetal washer being located at the side of the stacked arrangement remotefrom the first metal washer.

According to yet another aspect of the disclosure, provided is acomponent assembly having a stacked arrangement comprising an uppersheet part and a lower sheet part, of which at least one is formed as anorganic sheet composite part, with an auxiliary joining part and with atleast one apertured metal washer, wherein the auxiliary joining part hasa functional section having an undercut at one end and also has apiercing section at the other end having a lateral shaft surface and ashaft recess formed therein, wherein the metal washer contacts a surfaceof the organic sheet composite part, with the functional section or thepiercing section extending through an aperture of the metal washer andwherein washer material has been driven into the undercut or into the atleast one shaft recess, whereby the auxiliary joining part is joined tothe metal washer and wherein the other respective one of the undercut orof the shaft recess is in a holding engagement with a sheet part formedas a sheet metal part or with a further metal washer, with the sheetmetal part or the further metal washer being located at a side of thestacked arrangement remote from the first metal washer.

According to another aspect of the disclosure, provided is a componentassembly with a stacked arrangement of an upper sheet part and a lowersheet part of which at least one is formed as an organic sheet compositepart, with an auxiliary joining part having a first end and a second endand with at least one apertured metal washer, with the metal washercontacting a surface of the organic sheet composite part, with the firstend of the auxiliary joining part extending through an aperture of themetal washer and either being joined to the metal washer by embossing ofthe auxiliary joining part; or with washer material being so deformedthat it is driven into an undercut of the auxiliary joining part,whereby the auxiliary joining part is likewise joined to the metalwasher; and wherein the second end of the auxiliary joining part iseither in a holding engagement with a sheet part formed as a sheet metalpart or with a further metal washer, with the sheet metal part or themetal washer being located at the side of the stacked arrangement remotefrom the first metal washer.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be explained by way of example and with referenceto the drawings.

FIG. 1 shows a piercing tool which is used for the joining of two sheetmetal parts in accordance with the invention, in an open position at thestart of the joining process,

FIG. 2 shows the same tool as FIG. 1 in a second phase of the joiningprocess, in which the tool has been closed to the extent that the sheetmetal parts are pressed against one another,

FIG. 3 shows a further phase of the joining process in which theauxiliary joining part is just being punched through the sheet metalparts,

FIG. 4 shows the last phase in the joining process in which the sheetmetal parts are fully joined to one another by means of the auxiliaryjoining part in the fully closed state of the tool,

FIG. 5 shows a component assembly in accordance with the invention whichcan be obtained by the method illustrated in FIGS. 1-4,

FIG. 6 is an enlarged part section of FIG. 5 which shows the joiningposition between an auxiliary joining part and a metal washer of thecomponent assembly in more detail,

FIG. 7 shows a schematic representation of an alternative tool for thecarrying out of an alternative method in accordance with the inventionfor the joining of two sheet metal parts to one another, of which atleast one is formed as an organic sheet metal part,

FIG. 8A a representation partly sectioned in the longitudinal directionof the die button shown at the bottom in FIG. 7,

FIG. 8B shows a perspective illustration of the die button of FIG. 8A,

FIG. 9A shows a representation section in the longitudinal direction ofthe setting head of FIG. 7 illustrated at the top, with the sectionplane being placed in accordance with the arrows in the end view of FIG.9C,

FIG. 9B shows a perspective representation of the setting head of FIG.9A,

FIG. 9C shows an end view of the setting head of FIG. 9A seen frombelow,

FIG. 9D shows a view of a pressure plunger of the setting head of FIG.9A,

FIG. 9E shows a view of the nose piece of the setting head of FIG. 9A,

FIG. 10A shows a photographic image of an auxiliary joining part inaccordance with the invention,

FIG. 10B shows a representation of the one end of the auxiliary joiningpart of FIG. 10A after it has been embossed in order to achieve aform-fitted connection to the like-wise illustrated metal washer whichrepresents the result of the use of the setting head of FIGS. 9A to 9E,and

FIG. 10C shows a representation of the other end of the auxiliaryjoining part of FIG. 10A after it has been joined to the likewiseillustrated metal washer by deformation of the metal material of themetal washer in order to achieve a form-fitted connection with the metalwasher, which represents the results of the use of the die button inaccordance with FIG. 8A and 8B.

DETAILED DESCRIPTION

The piercing tool 11 which is only partly shown in FIG. 1 includes asetting head 13 and a die button 15 between which two sheet metal partsare arranged which are to be connected to one another, namely an uppersheet metal part 17 and a lower sheet metal part 19. In the illustratedembodiment both sheet metal parts 17, 19 are executed as organic sheetmetal parts, that is to say these consist of a non-metallic compositematerial, such as, a fiber reinforced plastic. It should be pointed outthat one or more intermediate layers can be arranged between the sheetmetal parts 17, 19, for example further organic sheet metal parts ormetallic sheet metal parts.

As illustrated the piercing or setting head 13 has an inner plunger 20,an outer plunger 21 surrounding it and also a hold-down member 22surrounding the outer plunger 21 which can be moved relative to oneanother with respect to a piercing direction S. A narrow projection,here ring-like plunger projection 27, is formed at an end face 25 of theouter plunger 22 facing the setting direction S, with the projectionbeing arranged adjacent to an inner spacer 29 defined by the outerplunger 21.

The die button 15 has at its upper side a trough-like mount 31 with anarrow die projection 35, here a ring-like die projection projectingfrom its base 33. Furthermore, the die button 15 has a central passage37 which is bordered by the die projection 35.

The joining of the two sheet metal parts 17, 19 takes place with the aidof two metal washers, namely an upper metal washer 41 and a lower metalwasher 43 and also of pierced rivet-like auxiliary joining part 45. Themetal washers 41, 43 each have an aperture 47, the diameter of whichcorresponds substantially to the outer diameter of the shaft part of theauxiliary joining part 45. In the starting configuration of FIG. 2 theupper metal washer 41 lies against the upper side of the upper sheetmetal part 17 and is acted on by the outer plunger 21. The lower metalwasher 43 is located in a mount 31 of the die button 15 and is held incontact by the die button at the lower side of the lower sheet metalpart 19. The auxiliary joining part 45 has a functional section 51 atone end and has a piercing section 53 at the other end. A respectivearrangement of a plurality of circumferential shaft grooves 55 extendingparallel to one another is provided both in the region of the functionalsection 51 and also in the region of the piercing section 53. Thegroove(s) in the region of the functional section 51 may be referred toherein as an undercut and referenced with numeral 56 in FIGS. 1-5. Theauxiliary joining part 45 is preferably manufactured of a metal suitablefor the piercing of sheet metals.

A piercing process shown in FIG. 3 is introduced by the lowering of theinner plunger 20 relative to the die button 15. The auxiliary joiningpart 45 is pressed by the inner plunger 20 through the upper sheet metalpart 17 and the lower sheet metal part 19, with piercing slugs 59 beingpunched out and being led away through the passage 37 of the die button15. During the piercing the auxiliary joining part 45 is passed throughthe apertures 47 of the sheet metal parts 17, 19. At the end of thepiercing process, the shaft grooves 55 of the functional section 51 arelocated in the region of the upper metal washer 41 while the shaftgrooves 55 of the piercing section 53 are located in the region of thelower metal washer 43.

Thereafter, the outer plunger 21 and the die button 15 are moved towardsone another with respect to the piercing direction S, with the plungerprojection 27 engaging into the upper metal washer 41 and deforming thislocally (FIG. 4). In the course of this deformation metallic material isdriven into or deformed into the closely disposed shaft grooves 55 sothat ultimately a stable joint connection results between the uppermetal washer 41 and the auxiliary joining part 45 (FIG. 6). In the sameway the die button projection 35 engages into the lower metal washer 43and brings about a local deformation, wherein metallic material is inturn driven into the closely disposed shaft grooves 55. Thus, a stablejoint connection results also between the lower metal washer 43 and theauxiliary joining part 45.

As a result a component assembly 60 is present as shown in FIG. 5 whichincludes two organic sheet metal parts 17, 19 which are firmly joined toone another. The arrangement of the two metal washers 41, 43 and of theauxiliary joining part 45 passed through the component stack clamps theorganic sheet metal part 17, 19 reliably against one another. It is thusnot necessary to anchor the auxiliary joining part 45 or furtherconnection elements in the material of the organic sheet metal parts 17,19. Should one of the sheet metal parts 17, 19 be a metallic sheet metalpart, then one of the two metal washers 41, 43 can be dispensed with.The auxiliary joining part 45 can then only be guided during thepiercing in such a way that either the shaft grooves 55 of thefunctional element 51 or the shaft grooves 55 of the piercing section 53are located in the upper sheet metal part 17 or in the lower sheet metalpart 19 respectively. In this case, pressure can be exerted on the sheetmetal parts 17, 19 in the normal manner in order to drive metallicworkpiece material into the shaft grooves 55.

On the whole the invention enables a reliable connection of sheet metalparts which at least forms organic sheet metal parts.

One is concerned here, as is customary for the attachment of fastenerelements, with a setting head 13 which is arranged at the upper tool ofa press or at an intermediate plate of the press, whereas the tool whichreceives the die button 15 is the intermediate plate of the press or thelower tool of the press. An inverse arrangement would also be possiblein which the setting head 13 is arranged at the lower tool of the pressor at an intermediate plate of the press while the die button 15 is thenlocated at the intermediate plate or at the upper tool of the press.

It is in no way essential to use a press for the attachment of thefastener element to the workpiece. By way of example a robot, forexample in accordance with the European patent 0 691 900 can be used ina known manner, with the die button 15 and the setting head then beingcarried by the robot. A punching tool or other tools can also be usedfor the attachment of the functional elements arrangement to the sheetmetal part, for example a tool in accordance with one of the followingprotective rights: DE-PS 197 47 267, EP 0 890 397 or DE-PS 197 01 088.

It is indeed generally customary to attach fastener elements 45 at aworkpiece with the central longitudinal axis 16 being verticallyarranged, an orientation of this kind is however in no way essential.Instead of this the central longitudinal axis 16 can have any desiredorientation in space. Accordingly, when geometric terms such as verticalor up or down or above or below are used in this application then thisis to be understood in such way that the designations are only to betypical to the orientation of the corresponding Figure and are in no wayto be interpreted in restrictive manner.

As can for example be seen from the short description of FIG. 2 and thesubsequent description of this FIG. 2 and also of FIG. 3 the tool isclosed to such an extent that the sheet metal parts are pressed againstone another. This is an important condition to ensure that the auxiliaryjoining part successfully pierces the sheet metal parts or the organicsheet metal parts and generates a clean aperture of the organic sheetmetal part or parts without fraying out of the latter and also a cleanpiercing slug.

In the following the embodiments in accordance with FIGS. 7 to 100 willbe described. In these Figures the same reference numerals will be usedfor parts as were used in the previous Figures, as far as thecorresponding parts in FIGS. 7 and 10C have the same function. Partswhich are additionally used or which have a significantly differentfunction are used with new reference numerals starting with thecharacteristic number 100. It will be understood that when using theprevious reference numerals in FIGS. 7 to 100 the previous descriptionapplies unless something is stated to the contrary.

FIG. 7 shows the die button 15 and the setting head the centrallongitudinal axes of which coincide. In this connection the die button15 is formed for reception in the lower tool of the press or in anintermediate plate of the press while the setting head is designed forreception in the intermediate plate of the press or in the upper tool ofthe press. An inverse arrangement is also possible, i.e. the die buttoncan also be mounted facing downwardly in the upper tool of the press orin an intermediate plate of the press, while the setting head is locatedfacing upwardly in the intermediate plate of the press or in the lowertool of the press respectively. It is however not essential to use apress with an intermediate plate. Moreover, other attachment devices forjoining parts can also be considered, such as, for example a robot orpower-operated tongues which move the setting head to the die button orvice versa.

No components of the press or of the sheet metal parts can be seen inFIG. 7 and the auxiliary joining part which is shown on its own in FIGS.10A to 10C simply extends out of the setting head in an exaggeratedmanner for the sake of representation.

The FIGS. 8A and 8B now show the details of a practical embodiment ofthe die button 15 which can also be used in a schematic representationof the embodiment of FIGS. 1 to 6.

As can in particular be seen from FIG. 8A the die button 15 has atwo-part housing 100, 102 with the lower part 102 being secured by bolts104 to the upper housing part 100. Within the housing 100, 102 there isa fixed cylinder 106, a fixed apertured disc 108 which is supported inthe radially inner region by the cylinder 106, a fixed spacer cylinder110 which is supported by the apertured disc 108 and the cylinder 106and also a fixed inner cylinder 112 which is equipped with a ringprojection 35 (or the die button projection). The components 102, 106,108, 110 and 112 all have a central opening which jointly bound apassage 114 through which the piercing slugs 59 that are produced can beled away or dispensed of. Furthermore, the die button 15 has a fixedouter cylinder 116 which is supported by the apertured disc 108 andindeed by the outer radial region of the apertured disc 108.

Between the outer side of the fixed cylinder 106 and the radially innerside of the upper housing part 100 and also beneath the apertured disc108 there is located a cylindrical hollow space 118 in which a supportring 122 supported by means of a spring pack 120 and restrictedlymovable in the axial direction of the die button is arranged. In thisexample the spring pack consists of a plurality of plate springs 124which are placed on one another and which are centered by the spacercylinder 106. The die button 15 furthermore includes an axially movableupper intermediate cylinder 126 and an axially movable lowerintermediate cylinder 128. Between the lower side of the lowerintermediate cylinder 128 and the axially restricted movable supportring 122 there are a plurality of axially aligned pressure pins 130which are located in a circular arrangement and which are guided throughindividual axially parallel bores 132 in the apertured disc, with theseaxially parallel bores being located in a circular arrangement aroundthe central hole of the apertured disc 108.

The manner of operation of the die button can be understood as follows:

A metal washer (not shown here) is first placed into the mount 31defined by the upper intermediate cylinder. The sheet metal parts whichare not shown here (17 and 19 in the previous FIGS. 1 to 6), for exampletwo organic sheet metal parts or one organic sheet metal part and onemetallic sheet metal part are placed above one another on the upper sideof the metal washer. During the closing movement of the press (notshown) the sheet metal parts are pressed together via the setting head13 (FIG. 7) and are pressed against the surface of the metal washerprovided in the mount and not shown here.

In the pressed together state of the sheet metal parts and of the metalwasher the sheet metal parts are pierced by means of the auxiliaryjoining part 45 (FIG. 7) driven by the setting head and the lower end ofthe auxiliary joining part 45 (FIG. 7) is introduced into the apertureof the metal washer. The piercing slug, i.e. the punched out materialfalls into the central passage 114 and can be disposed of through thecentral passage 114, optionally with the aid of an air blast. Duringthis working step the force of the spring pack 120 is sufficient anddimensioned in order to prevent a movement of the upper intermediatecylinder 126 by means of the support ring 122, the pressure pins 130 andthe lower intermediate cylinder 128. As soon as the press is about toclose completely, a considerably larger force is exerted onto the upperend face of the upper intermediate cylinder 126 and this deviatesbackwardly in the axial direction (downwardly in FIG. 8A) with thisdeviating movement bringing about a compression of the spring pack 120via the lower intermediate cylinder 128, the pressure pins 130 and thesupport ring 122.

As a result of this deviation movement and of the forces which arise inthis way on closing the press, the upper end face of the upper fixedinner cylinder 112, which forms the die button projection 35, is pressedinto the material of the apertured metal washer and deforms thismaterial in such a way that it flows into the undercut of the auxiliaryjoining part 45 and joins the auxiliary joining part to the aperturedmetal washer and connects the auxiliary joining part to the aperturedmetal washer in form-fitted manner.

In this example the auxiliary joining part is designed as shown in FIG.10A and the form-fitted connection of the corresponding end of theauxiliary joining part 45 with the metal washer is formed as shown inFIG. 10B. The end face of the auxiliary joining part projectsfractionally beyond the metal washer 43 and it can be seen that themetal washer has been indented in ring-like manner around the projectingend of the auxiliary joining part.

The manner of operation of the setting head 13 of FIG. 7 differs fromthat of the setting head 13 of FIGS. 1 to 4 and indeed principally inthe fact that instead of driving material of the metal washer 41 into anundercut of the auxiliary joining part the corresponding adjacent end ofthe metal washer 41 is embossed and thus joined to the metal washer 41or to the upper sheet metal part. For the setting head of FIGS. 9A-9E anauxiliary joining part 45 can be used in accordance with FIG. 10A, withthe result of the embossing of the auxiliary joining part being shown inFIG. 10B and being explained later in more detail. In this connection itshould however be noted that it is in no way necessary to use anauxiliary joining art 45 in accordance with FIG. 10A with undercuts atboth ends, but rather the auxiliary joining part can have a differentdesign, for example that of a circular cylinder without any features ofshape which differ from the jacket surface of a right cylinder.

In this example an auxiliary joining part 45 is used with undercuts inthe form of threads at both ends, as an undercut is necessary in orderto sensibly use the die button 15 in accordance with FIGS. 8A and 8B andthe provision of thread cylinders at both ends ensures that theauxiliary joining part 45 can never be inadvertedly used the wrong wayround because it is symmetrically designed.

The design and the manner of operation of the setting head 13 of FIGS.9A to 9E will now be described in detail.

The setting 13 is intended for incorporation into an upper tool of apress or into an intermediate plate of the press or into the lower toolof the press in an arrangement as is described above. The setting head13 can also be actuated by a robot or by power-operated tongues as islikewise described above.

The setting head consists of two main components in the form of an upperhousing part 140 and a lower housing part 142 which is secured by meansof bolts 144 to the upper part 140.

A spring abutment 146 is located coaxially within the lower housing partand serves as a support for the upper ends of a plurality of axiallyparallel coil spring elements 150 arranged around the centrallongitudinal axis 148 of the setting head. The spring abutment 146 alsoserves to support the bolt 152 as well as the massive disc 154. Thespring abutment 146, the bolt 152 and the massive disc 154 are firmlyarranged in the housing. The bolt 152 serves as a guide for a sleeve 158which is axially displaceable in a cylinder space 156 of the lowerhousing part 142 against which the coil springs 150 are braced. In thisconnection the individual coil springs 150 extend in axially parallelbores 160 of the displaceable sleeve 158 and are also positioned bythese bores 160 in the housing 102, 104 of the setting head 13.

Below the axially displaceable sleeve there is located an aperture discor a ring 160 with a central aperture of which the diameter is somewhatlarger than that of the bolt 152 which has an outer diameter which issomewhat smaller than the diameter of the hollow space 156. The axiallydisplaceable aperture disc 160 is thus biased in an open position of thepress or in a corresponding position of the robot or tongues (all notshown here) downwardly and in the direction of the fixed disc 154 by thecoil springs 150 via the displaceable sleeve 158.

Beneath the fixed solid disc 154 there is likewise located a fixedpressure plunger 162 (see FIG. 9D) which is fixedly attached to themassive disc 154 by means of an apertured ring 164 and a sleeve 166which can be screwed into the lower housing part 152 and which firmlyholds the ring 164. The lower end of the pressure plunger has acylindrical jacket surface, but in the example shown here in FIG. 9Dalso has three longitudinal slots 168 so that three plunger tongues 170remain (the number of the longitudinal slots 168 and of the plungertongues is not critical, three is however preferred).

FIG. 9D shows a detailed view of the pressure plunger 162 of FIG. 9A.The pressure plunger having a substantially cylindrical outer shape withthree plunger tongues 172 at an end thereof and a base section 173 atthe other end. The base section 173 has a slightly conical surface whichis adapted and arranged in such a way that it cooperates with theapertured ring 164 to fix it to the massive disc 154 of the setting head13 (see FIG. 9A).

The pressure plunger 162, i.e. its plunger tongues 170 are guided in ahollow space of a nose piece 172 (see FIG. 9E) which is axiallydisplaceable on the pressure plunger 162, with the lower end of theaxially displaceable nose piece 172 having a shape at the inner sidewhich is complementary to the plunger tongues 170 (as is evident fromFIG. 9C) and indeed over an axial length which corresponds approximatelyto the axial movement capability of the nose piece 172. The upper end ofthe axially displaceable nose piece 172 is conically formed at its outerside so that it is secured by the conically converging end of the sleeve166 at the inner side against loss from the setting head 13. Above theinner side of the conically converging end of the sleeve 166 there islocated a cylindrical space which is large enough in order to permit theaxial movability of the nose piece 172.

Between the axially displaceable nose piece 172 and the movable aperturedisc are located axially parallel pressure pins 174 arranged in acircle, which extend through correspondingly arranged bores of the soliddisc 154 in order to engage at their lower ends at the nose piece and tocontact the underside of the axially displaceable ring 160 at theirupper ends.

In an open position of the press or of the robot that is used or of thetongues that are used the setting head 13 is in the illustrated positionin which the compression coil springs 150 are pressed downwardly via theaxially displaceable sleeve 158, the axially displaceable ring 160 andthe pressure pins 170 press the nose piece 172 downwardly. The front(lower) end of the nose piece 172 thus projects beyond the lower freeend face of the plunger tongues 170. The one end of the auxiliaryjoining part is inserted by hand into the correspondingly dimensionedmount 176 at the lower end of the displaceable nose piece and can beheld there by a small quantity of grease or magnetically or by a springring (all not shown).

FIG. 9E shows a detailed view of the nose piece 172 of FIG. 9A, one canclearly see the conical outer surface 167 adapted to cooperate with thesleeve 166 (see FIG. 9A) and the mount 176 adjacent to the end face 25having the plunger projection 27. The mount 176 is clearly configured atits center to receive the three plunger tongues 170 of the pressureplunger 162.

One can see, like from from FIG. 9A, that the lower end face of the nosepiece has the mount 176 (here in the shape of a ring recess) for a metalwasher such as 41 in FIG. 1. The metal washer 41 can likewise be held bymeans of a small quantity of grease, magnetically or by means of springelements such as polyurethane cushions which engage outwardly at themetal washer. The plunger tongues 170 are dimensioned in such a way thatthey emboss the end face of the corresponding end of the auxiliaryjoining part 45 at three outwardly displaced positions, as can be seenfrom the impressions 178 of FIG. 10B.

The embossing takes place during the corresponding movement of the robotor of the tongues (all not shown). During the corresponding closingmovement the lower end of the nose piece 172 or the lower side of ametal washer 41 (not shown) held therein presses against the upper sideof the upper sheet metal part 17 and presses the two sheet metal parts17 and 19 together and in addition presses any metal washers such as 41,43 which are provided against the sheet metal parts. I.e. the stack ofthe sheet metal parts and metal washer(s) is pressed together. The forcewhich is exerted from the coil springs 150 via the displaceable sleeve158, the ring 160 and the pressure pins 174 on the nose piece 172 issufficient for this in order to avoid an upwardly directed deviationmovement of the nose piece 172. The force which acts on a nose piece 172from below first arises in the last phase of the closing of the press orof a corresponding movement of the robot or of the tongues to such anextent that the nose piece deviates upwardly and the pressure plunger162 drives the auxiliary joining part 45 through the sheet metal partsand pierces these and the plunger tongues 170 subsequently emboss theupper free end of the auxiliary joining part.

One notes from this FIG. 10B that the free end of the auxiliary joiningpin 45 is pressed in at three positions angularly displaced around thecentral longitudinal axis and thus overlaps the upper side of thecorresponding metal washer at three positions. The end of the auxiliaryjoining part projects fractionally beyond the metal washer 41. One cansee from FIG. 10B that the free ends of the plunger tongues 170 areimpressed at the same angular position into the upper surface of themetal washer 41. Through the embossing of the free end of the auxiliaryjoining pin 45 the auxiliary joining pin is joined in form-fitted mannerto the metal washer 41. This can also be associated with a localdeformation of the metal washer 41.

It will be understood that the provision of a thread cylinder at thecorresponding end of the auxiliary joining part 45 is notdisadvantageous even though it is not necessary. After the connection ofthe sheet metal parts the nose piece 172 is pressed back into thestarting position of FIG. 9A by the compression coil springs 150 throughan opening of the press or a corresponding movement of the robot or of apower-operated tongue and the plate springs 124 of FIG. 8A guide theupper and lower intermediate cylinders 126 and 128 back into theirstarting position.

It is not necessary when using the illustrated setting head 13 tooperate with a metal washer 41. While the upper sheet metal part is ametallic sheet metal part, i.e. not an organic sheet metal part, themetal washer can be dispensed with and the corresponding end of theauxiliary joining part 45 can be directly connected by embossing withthe metallic sheet metal part.

It should also be pointed out that the die button 15 can also bedesigned similarly to the setting head 13 so that there also thecorresponding end of the auxiliary joining part can be joined by meansof embossing the metal washer 43 or to the lower sheet metal part whenthe latter is a metallic sheet metal part. For this it is simplynecessary to provide the upper end of the fixed inner upper cylinder 112with a somewhat smaller internal diameter and to provide the upper end,corresponding to the lower end of the pressure plunger of FIG. 9A withcutouts and plunger tongues arranged there between. Such plunger tonguesof the upper inner cylinder 112 of the die button can correspond incross-sectional shape and size to those of the pressure plunger. Thecutouts can have an axial depth which is smaller than that of thelongitudinal slots 168 of the pressure plunger 162.

Furthermore, it should be mentioned that the metal washer 41 and/or themetal washer 43 do not in any way have to be previously pierced, butrather the piercing in these washers could take place by means of theauxiliary joining part during the piercing in the same operation as thepiercing of the sheet metal parts takes place.

Normally, the auxiliary joining parts that are used are somewhatstronger than a bolt of the class 8 in accordance with the DIN norm,this is however not essential, it depends on the strength of the partsthat are to be connected.

The component assembly of the present invention is expediently such thatthe at least one shaft recess 55 is formed as a circumferential groove.Alternatively the at least one shaft recess may be formed as a thread.In another embodiment a plurality of shaft recesses 55, in particular aplurality of parallel circumferential grooves, are provided at the shaftsurface of the piercing section 53. Moreover the undercut mayexpediently have the same shaping or design as the shaft recess, so thatthe functional part is symmetrical and it does not matter which wayround it is inserted into the stacked arrangement.

In the component assembly of the invention the organic sheet metal partmay consist of a composite material, in particular of a fiber reinforcedduroplastic material or a fiber reinforced thermoplastic material.

It is particularly expedient when the lower sheet metal part 19 isformed as an organic sheet metal part and the metal washer 43 isarranged at the lower side of the lower sheet metal part. Alternatively,the upper sheet metal part 17 may be formed as an organic sheet metalpart and the metal washer 41 is then arranged at the upper side of theupper sheet metal part.

In another embodiment of the invention both the upper sheet metal part17 and also the lower sheet metal part 19 are formed as organic sheetmetal parts, with a lower metal washer 43 contacting the lower side ofthe lower organic sheet metal part 19, an upper metal washer 41 alignedwith the lower metal washer 43 contacting the upper side of the upperorganic sheet metal part 17 and the auxiliary joining part 45 extendingthrough the apertures 47 of both metal washers 41, 43.

The auxiliary joining part 45 is expediently formed as a cylindricalpart with an at least substantially constant cross-sectional shape andsize apart from the undercut of the shaft recess. Moreover, theauxiliary joining part 45 is preferably formed as a cylindrical parthaving a cross-sectional shape and size which, apart from any undercutswhich may optionally be provided at the first and second ends, is atleast substantially constant over its entire length.

The present invention also comprises a setting head 13 for carrying outthe methods described herein and for the manufacture of any componentassembly as described herein.

The present invention also extends to a die button 15 for carrying outany of the methods described herein or for manufacture of any of thecomponent assemblies described herein.

REFERENCE NUMERAL LIST

11 punching tool

13 setting head

15 die button

16 central longitudinal axis

17 upper sheet metal part

19 lower sheet metal part

20 inner plunger

21 outer plunger

22 hold-down member

25 end face

27 plunger projection

29 internal space

31 mount

33 base

35 die button projection

37 channel

41 upper metal washer

43 lower metal washer

45 auxiliary joining part

47 aperture

51 functional section

53 piercing section

55 shaft groove

59 piercing slug

60 component assembly

100 upper part of the housing

102 lower part of the housing

104 bolts

106 fixed cylinder

108 fixed aperture disc

110 fixed spacer cylinder

112 fixed inner cylinder with die button projection 35

114 central passage for the disposal of piercing slugs

116 fixed outer cylinder of the die button

118 cylindrical hollow space

120 spring pack

122 movable support ring

124 blade springs

126 upper axially movable intermediate cylinder

128 lower axially movable intermediate cylinder

130 pressure pins

132 axially parallel bores of the aperture disc 108

140 upper part of the housing of the setting head 13

142 lower part of the housing of the setting head 13

144 bolts

146 spring abutment

148 central longitudinal axis of the setting head 13

150 compression coil spring

152 bolt

154 solid disc

156 cylinder space of the lower housing part 142

158 axially movable sleeve

160 aperture disc

162 pressure plunger

164 apertured ring

166 sleeve

167 conical outer surface 168 longitudinal slits of the pressure plunger

170 plunger tongues

172 nose piece

173 base section

174 pressure pins

176 mount for the auxiliary joining part 45

178 impressions

S piercing direction

1. A method for the connection of an upper sheet part (17) and a lowersheet part (19) of which at least one is executed as an organic sheetcomposite part, with the aid of an auxiliary joining part (45) and atleast one metal washer (41, 43) having an aperture, wherein theauxiliary joining part (45) has first and second ends, there being afunctional section (51) with an undercut (56) at one of said ends and apiercing section (53) with a lateral shaft surface and a shaft recess(55) formed therein at the other of said ends, the method comprising thefollowing steps: i) the upper sheet part (17), the lower sheet part (19)and the metal washer (41, 43) are brought into a stacked arrangement insuch a way that the metal washer (41, 43) contacts the organic sheetcomposite part, ii) the piercing section (53) of the auxiliary joiningpart (45) is used in order to pierce a slug (59) from the stacked sheetparts (17, 19), iii) either the functional section (51) or the piercingsection (53) is passed through an aperture (47) of the metal washer (41,43) until the undercut (56) or the at least one shaft recess (55) is atleast partly surrounded by washer material, iv) an adequate pressure isexerted on the metal washer (41, 43) in order to drive washer materialinto the at least one shaft recess (55) or into the undercut (56) andthereby to join the auxiliary joining part (45) to the metal washer (41,43), and v) the other respective one of the undercut or of the shaftrecess is brought into a holding engagement with a sheet part formed asa sheet metal part or with a further metal washer (41, 43), with thesheet metal part or the further metal washer being located at the sideof the stacked arrangement remote from the first metal washer.
 2. Amethod in accordance with claim 1, wherein the same shaping is selectedfor the undercut as for the shaft recess.
 3. A method in accordance withclaim 1, wherein the metal washer (43) is positioned at a lower side ofthe lower sheet part (19) which is executed as an organic sheetcomposite part by means of a die button (15) which has a mount (31) forthe metal washer (43) and a passage (37) for leading away the piercingslug (59).
 4. A method in accordance with claim 3, wherein in step (iv)the metal washer (43) is deformed in the region of the rim of theaperture (47) by means of at least one projection (35) provided in themount (31) of the die button (15), the projection optionally being aring projection.
 5. A method in accordance with claim 1, wherein themetal washer (41) is positioned by means of a setting head (13) at theupper side of the upper sheet part (17) executed as an organic sheetcomposite part, the setting head having a plunger and the auxiliaryjoining part (45) being passed through the aperture (47) of the metalwasher (41) by means of the plunger (20) of the setting head (13) actingon the functional section (51).
 6. A method in accordance with claim 5,wherein in the step (iv) the metal washer (41) is deformed in the regionof the rim of the aperture (47) of this metal washer (41) by means of aprojection (27) provided at a lower side of an outer plunger (21) of thesetting head (13) acting on the sheet metal washer (41), the projection(27) provided at the lower side of the outer plunger optionally being aring projection.
 7. A method in accordance with claim 1, wherein boththe upper sheet part (17) and also the lower sheet part (19) are formedas organic sheet composite parts, with a lower metal washer (43) beingpositioned by means of a die button (15) at the lower side of the lowerorganic sheet composite part (19) and an upper metal washer (41) beingpositioned at an upper side of the upper organic sheet composite part(17) by means of a setting head (13) and being aligned with the lowermetal washer (43).
 8. A method in accordance with claim 1, wherein thesheet parts are pressed against one another in the step (ii).
 9. Amethod for the connection of an upper sheet part (17) and of a lowersheet part (19) of which at least one is formed as an organic sheetcomposite part, with the aid of an auxiliary joining part (45) which hasa first end and a second end and also with the aid of a pierced metalwasher (41, 43), the method comprising the following steps: (i) theupper sheet part (17), the lower sheet part (19) and the metal washer(41, 43) are brought into a stacked arrangement in such a way that themetal washer (41, 43) contacts the organic sheet composite part, (ii) apiercing section (53) of the auxiliary joining part (45) is exploited topunch a slug (59) from the stacked sheet parts (17, 19), (iii) the firstend of the auxiliary joining part is passed through an aperture (47) ofthe metal washer (41, 43) to such an extent that it is at least partlysurrounded by washer material, and, either, (iva) an adequate pressureis exerted onto the sheet metal washer (41, 43) in order to drive washermaterial into at least one undercut (56) of the first end of theauxiliary joining part (45), in order to join the auxiliary joining part(45) to the metal washer (41, 43), or (ivb) the first end of theauxiliary joining part (45) is embossed in order to hereby join theauxiliary joining part (45) in the region of the first end to the metalwasher and the second end of the auxiliary joining part (45) either (va)is brought by embossing into a holding engagement with a sheet partformed as a sheet metal part or with a further metal washer (41, 43),with the sheet metal part or the metal washer being located at the sideof the stacked arrangement remote from the first metal washer, or (vb)is joined by deformation of the sheet metal part or by deformation of afurther metal washer (41, 43) to the sheet metal part or to the furthermetal washer, with the sheet metal part or the further metal washerbeing located at the side of the stacked arrangement remote from thefirst metal washer.
 10. A method in accordance with claim 9, wherein themetal washer (43) is positioned at a lower side of the lower sheet metalpart (19) which is executed as an organic sheet composite part, by meansof a die button (15) which has a mount (31) for the metal washer (43)and a passage (114) for leading away the piercing slug (59).
 11. Amethod in accordance with claim 9, wherein both the upper sheet part(17) and also the lower sheet part (19) are executed as organic sheetcomposite parts, with a lower metal washer (43) being positioned bymeans of a die button (15) at the lower side of the lower organic sheetcomposite part (19) and an upper sheet metal washer (14) beingpositioned by means of a setting head (13) at an upper side of the upperorganic sheet composite part (17) and aligned with the lower metalwasher (43).
 12. A method in accordance with claim 9, wherein the sheetparts (17, 19) are pressed against one another in step (ii).
 13. Amethod in accordance with claim 1, wherein the stacked arrangement isformed with one or more intermediate layers located between the uppersheet part and the lower sheet part.
 14. A method in accordance withclaim 9, wherein an auxiliary joining part is used in the form of acylindrical pin formed as a cylindrical part having a cross-sectionalshape and size which is at least substantially constant over its entirelength.
 15. A component assembly (60) having a stacked arrangementcomprising an upper sheet part (17) and a lower sheet part (19), ofwhich at least one is formed as an organic sheet composite part, with anauxiliary joining part (45) and with at least one apertured metal washer(41, 43), wherein the auxiliary joining part (45) has a functionalsection (51) having an undercut (56) at one end and also has a piercingsection (53) at the other end having a lateral shaft surface and a shaftrecess (55) formed therein, wherein the metal washer (41, 43) contacts asurface of the organic sheet composite part, with the functional section(51) or the piercing section (53) extending through an aperture (47) ofthe metal washer (41, 43) and wherein washer material has been driveninto the undercut (56) or into the at least one shaft recess (55),whereby the auxiliary joining part (45) is joined to the metal washer(41, 43) and wherein the other respective one of the undercut or of theshaft recess is in a holding engagement with a sheet part formed as asheet metal part or with a further metal washer (41, 43), with the sheetmetal part or the further metal washer being located at a side of thestacked arrangement remote from the first metal washer.
 16. A componentassembly (60) with a stacked arrangement of an upper sheet part (17) anda lower sheet part (19) of which at least one is formed as an organicsheet composite part, with an auxiliary joining part (45) having a firstend and a second end and with at least one apertured metal washer (41,43), with the metal washer (41, 43) contacting a surface of the organicsheet composite part, with the first end of the auxiliary joining part(45) extending through an aperture (47) of the metal washer (41, 43) andeither being joined to the metal washer (41) by embossing of theauxiliary joining part; or with washer material being so deformed thatit is driven into an undercut of the auxiliary joining part, whereby theauxiliary joining part (45) is likewise joined to the metal washer (41,43); and wherein the second end of the auxiliary joining part is eitherin a holding engagement with a sheet part formed as a sheet metal partor with a further metal washer (43), with the sheet metal part or themetal washer being located at the side of the stacked arrangement remotefrom the first metal washer (41).
 17. A component assembly in accordancewith claim 16, wherein the second end of the auxiliary joining parteither has an embossing whereby it is joined to the sheet metal part orto the further metal washer (43); or is joined to the sheet metal partor to the further metal washer (43) by a deformation of the material ofthe sheet metal part or of the further metal washer (43) into anundercut of the auxiliary joining part.
 18. A component assembly inaccordance with claim 16, wherein both the upper sheet part (17) andalso the lower sheet part (19) are formed as organic sheet compositeparts, with a lower metal washer (43) contacting the lower side of thelower sheet part (19), with an upper metal washer (41) contacting theupper side of the upper sheet part (17) and being aligned with the lowermetal washer (43); and with the auxiliary joining part (45) extendingthrough the apertures (47) of both metal washers (41, 43).
 19. Acomponent assembly in accordance with claim 15, wherein the stackedarrangement includes one or more intermediate layers, which are locatedbetween the upper sheet part and the lower sheet part.
 20. A componentassembly in accordance with claim 16, wherein the stacked arrangementincludes one or more intermediate layers, which are located between theupper sheet part and the lower sheet part.
 21. A component assembly inaccordance with claim 16, wherein said auxiliary joining part comprisesa cylindrical pin (45) formed as a cylindrical part having across-sectional shape and size which is at least substantially constantover its entire length.